Lexus RX400h, Hybrid 3 2006

Valve Covers

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Using a clip remover, remove the engine side cover.

    Click image to see an enlarged view

    Fig. Use a clip removal tool to remove the engine side cover

  4.  
  5. Drain the coolant and engine oil.
  6.  
  7. Remove front upper center suspension brace subassembly, as follows:
    1. Remove the 4 nuts and front suspension brace subassembly.
    2.  
    3. Install the 4 shock absorber nuts and tighten to 59 ft .lbs. (80 Nm).

      Click image to see an enlarged view

      Fig. Remove front upper center suspension brace subassembly

    4.  

  8.  
  9. Remove the air cleaner cap w/ inlet, as follows:
    1. Remove the 2 bolts, 4 clamps and air cleaner cap w/ inlet.
    2.  
    3. Remove the air cleaner filter element from the air cleaner case.
    4.  

  10.  
  11. Remove the air cleaner case w/ resonator.
  12.  
  13. Remove the emission control valve set.
  14.  
  15. Remove the intake air surge tank.
  16.  
  17. Disconnect the inlet radiator hose.
  18.  
  19. Remove the ignition coil assembly
  20.  
  21. Remove the cylinder head cover sub-assembly, as follows:
    1. Remove the 2 engine wire harness clamps.
    2.  
    3. Remove the 3 nuts and disconnect the engine wire harness.

      Click image to see an enlarged view

      Fig. Remove the 2 clamps and 3 nuts

    4.  
    5. Remove the 9 bolts and the cylinder head cover.

      Click image to see an enlarged view

      Fig. Remove the 9 bolts and the cylinder head cover

    6.  

  22.  
  23. Remove left cylinder head cover sub-assembly:
    1. Using an E6 Torx® socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.

      Click image to see an enlarged view

      Fig. Use a Torx® wrench to remove the 2 bolts, then disconnect the engine wire harness protector

    2.  
    3. Put on insulating gloves, then remove the 2 engine wire harness clamps.

      Click image to see an enlarged view

      Fig. Put on insulating gloves, then remove the 2 engine wire harness clamps

    4.  
    5. Remove the 2 bolts and 2 brackets.
    6.  
    7. Remove the 9 bolts and the cylinder head cover.

      Click image to see an enlarged view

      Fig. Remove the 9 bolts and the cylinder head cover

    8.  

  24.  
  25. Thoroughly clean the gasket mating surfaces.
  26.  

To install:

  1. Install the cylinder head cover sub-assembly, as follows:
    1. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown in the illustration. Make sure all oil residue is removed from the contact surfaces prior to installing the seal packing.
      WARNING
      Install the cylinder head cover within 3 minutes after applying seal packing. Do NOT start the engine within 2 hours after installing.



      Click image to see an enlarged view

      Fig. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown

    2.  
    3. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps to a final torque of 71 inch lbs. (8 Nm).
    4.  
    5. Install the engine wire harness with the 3 nuts and 2 clamps. Tighten to 74 inch lbs. (8.4 Nm).
    6.  

  2.  
  3. Install the left cylinder head cover sub-assembly:
    1. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown in the illustration. Make sure all oil residue is removed from the contact surfaces prior to installing the seal packing.
      WARNING
      Install the cylinder head cover within 3 minutes after applying seal packing. Do NOT start the engine within 2 hours after installing.



      Click image to see an enlarged view

      Fig. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown

    2.  

  4.  
  5. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps to a final torque of 71 inch lbs. (8 Nm).
    1. Install the 2 brackets with the 2 bolts.
    2.  
    3. Install the 2 engine wire harness clamps.
      WARNING
      Wear insulating gloves.

    4.  
    5. Using an E6 Torx® socket wrench, install the engine wire harness protector with the 2 bolts. Tighten to 74 inch lbs. (8.4 Nm).
    6.  

  6.  
  7. Install the ignition coil assembly. Tighten the retainers to 71 inch lbs. (8 Nm).
  8.  
  9. Connect the radiator inlet hose.
  10.  
  11. Install the intake air surge tank.
  12.  
  13. Install the emission control valve set.
  14.  
  15. Install the air cleaner case w/ resonator.
  16.  
  17. Install the air cleaner cap w/ inlet.
  18.  
  19. Install the front upper center suspension brace subassembly.
  20.  
  21. Add the proper and amount of engine oil and coolant to the engine.
  22.  
  23. Check for engine coolant and/or oil leaks.
  24.  
  25. Install the engine side cover:
  26.  
  27. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  28.  

 
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